Method of manufacturing a molded composite elastomeric foam sheet innersole

ABSTRACT

A shoe-innersole material for use in providing cushioning and support in footwear, and a method of manufacturing the shoe-innersole material, the shoe innersole comprising a heel and an arch section composed of a molded, elastomeric polyurethane foam material of low compression set, the heel and arch sections directly bonded in the molding process to a full-sole material composed either of foam or a solid, flexible sheet material.

BACKGROUND OF THE INVENTION

Shoe innersoles are employed with articles of footwear for a variety ofpurposes, such as to provide comfort, distribution of weight, arch orheel support and insulating qualities. Innersoles may be employed inathletic, jogging or running shoes and in general footwear and in boots,such as cross-country boots, and in other articles of footwear.

An innersole for an athletic shoe is described, for example, in U.S.Pat. No. 4,187,621, wherein the innersole comprises a laminate of twolayers which is cut and conformed in contour to the last shape of theshoe, and which has an upper layer and a lower layer of different anddefined compression sets. Typically, both of the upper and lower layerscomprise cross-linked, closed-cell polyethylene polymers of differentdensities. However, it has been found that the polyethylene foamemployed in such innersoles is not wholly satisfactory, since thepolyethylene foam tends to break down in use, due to the poorcompression set of the polyethylene foam, with a considerable reductionin cushioning, particularly in the heel section and the ball section ofthe foot and may tend to reduce cushioning to unsatisfactory comfortlevels. Also, this laminate, while permitting the two-layer foammaterial to conform to the shape of the wearer's foot, does not providebreathing properties.

Various polymers, including polyurethane foam materials, have beensuggested for use in innersoles. For example, U.S. Pat. No. 3,781,231,issued Dec. 25, 1973, describes a resilient, cross-linked, hydrophilic,open-cell, polymer foam material which may be used to cast foams ofvarying thickness, and the insoles may be cut to shoe-sole shape fromsheets of the cast foam. Other shoe innersoles have been prepared havinga laminated construction, such as described in U.S. Pat. No. 3,730,169,wherein a laminated, cushion innersole is described as comprisign anupper layer of generally smooth, low-friction material, the bottom layerof a generally resilient material, and an intermediate, permanentlydeformed cushion layer comprising an open-cell, polyurethane foammaterial. The innersole requires three separate layers of flat sheetmaterial, with the object being to have the innersole deformedpermanently on wearing, to conform the innersole to the shape of thewearer's foot; that is, to prepare a self-shaping innersole. Thepolyurethane material provides for plastic deformation to conform to thefoot shape, while the bottom layer is adhesively secured to form anonskidding layer.

Other flat-type, multiple-layer, innersole materials are described, forexample, in U.S. Pat. No. 4,055,699, which innersole requires a dense,cross-linked polyolefin layer and an aluminum-coated moisture barrierlayer, to provide insulation to the foot of the wearer. A protectiveinsert for a shoe is also described in U.S. Pat. No. 3,638,336, whereina foam closed-cell layer is laminated to a face layer of fabric, withthe insert being contoured to conform to the insole of the shoe, andhaving a sculptured heel portion to cup the heel of the wearer in use.Another insole designed for heat insulation is described in U.K.specification No. 1,243,575, wherein a flexible backing of leather orsynthetic plastic material is secured to a heat-insulating layer ofexpandable polyethylene.

While prior innersoles, for use in articles of footwear, have beensatisfactory generally for certains specific purposes, there aredisadvantages associated with such innersoles, such as the breaking downof the foam layer with closed-cell, polyethylene-type innersoles, andthe problems associated with the cost of laminating, forming andmanufacturing the other innersoles. Therefore, there is a need for animproved innersole material and method of manufacture, which providesadditional advantages and overcomes at least some of the disadvantagesof the prior-art innersoles and methods.

SUMMARY OF THE INVENTION

The invention relates to an improved innersole material and a method ofmanufacturing shoe innersoles. In particular, the invention concerns animproved innersole for use in articles of footwear which have a molded,polyurethane foam heel and arch section directly bonded to a rigid,lower, last material or to a flexible, foam or solid shoe-uppermaterial.

It has been discovered that molded, contoured, shoe innersole materialsof improved structural and design characteristics can be prepared andprovide specific cushioning, support and improved innersole structuralcharacteristics, through the use of a molded heel and arch sectionformed of a substantially nondeformable, open-cell, elastomeric,polyurethane foam material of low and defined compression set, and whichelastomeric material is not subject to rapid breakdown and loss ofcushioning during use, and which material provides, in the heel and archsections, cushioning and support for the heel and the arch of the footof the wearer. Further, it has been discovered that such molded,polyurethane materials of the heel and arch sections may extend to thefull-sole shape, rather than only to the heel and arch sections, andfurther may be bonded directly in the molded process, without the use ofother adhesives, to a flexible, shoe-upper material or to a rigid lastmaterial or to both materials during the molding process. This methodeliminates the cost and difficulties associated with employing variouslayers of adhesives, laminations or other bonding techniques of theprior art. The molded shoe innersole material of the invention can bemolded alone or with a full- or half-sole section, or in combinationwith numerous flexible and stiff sheet materials, to provide the desiredlook and feel for the particular purpose for which the innersolematerial is to be used.

The method of manufacturing the shoe-innersole material provides for aninjection-molding of an expandable, reactable, polyurethane foammaterial which forms a substantially nondeformable, elastomeric foammaterial heel section, and yet which is directly bonded, during thecuring reaction in the mold, to a sheet material which is includedwithin the mold. The elastomeric foam, contoured heel section can bemolded also directly to the main structural component of the shoe; thatis, to the shoe last material, or, if desired, directly to theshoe-upper material or to both directly in the mold and during themolding process. The improved shoe-innersole material of the inventionprovides for a unique, integral, bonded innersole and a low-cost andefficient method of preparing the improved innersole material.

The innersole of the invention has a contoured heel and arch sectiontherein, the heel and arch sections composed of a substantiallyopen-cell and nondeformable, elastomeric polyurethane polymer, whichpolymer is expanded, in situ, in the molding process within a moldcavity, to form the contoured heel and arch section. The elastomericpolymer forms, during the reacting and curing process in the mold, thematerial which directly bonds to the sheet material employed in themold. Polyurethane polymers are obtained from the reaction of anisocyanate and a polyol, which reaction typically starts in admixture atroom temperature. Polyurethane polymers may comprise a flexible,open-cell-type foam, a rigid foam employed, for example, for insulation,and elastomers. The flexible polyurethane foams are not suitable for thepurposes of the invention, since they tend to be soft, flexible and verylow-density materials which are subject to deformation during use, whilethe rigid urethanes are also unsuitable.

The polyurethane polymers employed in the present invention comprisethose polyurethane elastomers prepared typically by reaction ofmethylene diisocyanate or toluene diisocyanate with polyols, whicheither can be polyethers or polyesters, and preferably polyesters, toprepare a polymeric elastomer having an average molecular weightgenerally of about 1,000 to 10,000; for example, 4,000 to 8,000. Thepolyurethane elastomers may be made with various diol extenders and maybe cured with a variety of curing agents, such as diamine compoundsalone or in various blends. The urethane elastomer uses a curing agent,such that the elastomer cures with time and provides essentially linearcross-linked polymers. The polyurethane elastomeric composition isusually a two-part composition mixed usually just prior to or oninjection into the mold cavity, so that all or substantially all of thereaction occurs within the mold cavity after injection. One componentcomprises the isocyanate and typically the other component comprises apolyol, a curing catalyst, a blowing agent and, if required,cell-control surfactants and various other additives, to improvespecific properties of the urethane elastomers; for example, fillers,fibers, ultraviolet-light absorbers, oxidation inhibitors, stabilizers,antioxidants, etc. Microcellular polyurethane elastomers; for example,from about 3 to 30 pounds per cubic foot, such as from 4 to 20 pounds,are typically produced by the reaction of components containing water,halocarbons or azo compounds, so as to form a foamable, elastomericresin polymer. The reaction typically proceeds in the closed mold with arise in temperature or an exotherm, and, thereafter, the elastomericpolymer is cured. The formulations of foamable or expandable,elastomeric, cured polyurethane polymers are well known.

A wide variety of sheet materials may be employed as the upper or lowersheet material of the innersole, to include solid, cellular andfabric-type, flat-sheet upper material, depending upon the particularuse for the innersole material. For example, various urethane, vinyl andrubber-latex, flat-sheet foam layers may be employed, either alone orhaving one or both surfaces laminated or adhesively secured or otherwiseformed to a knitted or woven fabric layer, such as a cotton, polyesteror stretchable fabric material, which forms the upper or lower surfaceof the flexible sheet material. In addition, the sheet material maycomprise a solid, flexible layer, such as one composed of urethane orvinyl sheet material having an imitation-leather, upper-surfaceappearance, or which may be secured to a fibrous sheet material, such asa woven or knitted fabric. In addition and importantly, in view of theinjection process, the innersole material may comprise a flexible, uppersheet material of natural leather, such as of a thin, natural leatherhaving a finished upper surface and a lower rougher surface; forexample, a smooth-finished or suede-like surface, either on the upper orlower surface. Of course, man-made imitation-leather materials ofvarious types also may be employed.

The foam materials employed as the upper, flexible sheet material maycomprise open-cell-foam-type, flat-sheet layers, typically such asopen-cell, rubber-latex-type material or a vinyl-coated fabric, such asCapilair (a product of Uniroyal, Inc.), or other material which is apolymeric-type material which has the ability to absorb moisture and tobreathe; thus making the upper sheet material in footwear morecomfortable and hygenic. Often such polymeric material contains aninterconnecting, open network of microscopic cells or channels, and mayextend throughout the depth of the material, with the outer surface ofthe material being hydrophobic and, thus, water-repellent. Suchpolymeric materials may include a foam layer and polyester or cottonbackings on one or both surfaces thereof. Generally, it is desirable toprovide an upper, flexible material having a rough, rather than asmooth, back surface in contact with the expandable, elastomericpolyurethane material, in order to provide improved adhesive strengthbetween the contoured heel section and the upper material.

Another material which may be employed in the process includes ashoe-last material about which the shoe or a particular type of footwearis constructed. Such material includes, but is not limited to, materialsknown as Texon or Bontex-like materials which are fairly rigid,resin-impregnated, fibrous-type materials. It has been discovered thatsuch materials may be employed in the process and in the contouredinnersole of the invention, by placing the material in the mold andinjecting the elastomeric polyurethane resin over the material, to bonddirectly the rigid last material to the lower surface of the contoured,elastomeric, polyurethane foam heel and arch sections. Generally, thelast material is employed in the general shape of the foot to beemployed on the footwear. Where only a half-heel section is injected,rather than a full-heel section, then the remaining portion of the footsection of the upper surface of the last material is adhesively bondedor otherwise secured to any flexible, upper shoe material. Thus, thecontoured innersole of the invention may comprise a lower, rigid,last-type material bonded at the heel portion to the lower-level, flatsurface of the foam heel section, with an upper, flexible, soft foam orsolid and typically fabric upper material bonded to the upper surface ofthe heel section and following the contours thereof, and with theforward section of the last material and the upper flexible sheetmaterial directly bonded together through the use of separate adhesivesor bonding techniques, to provide a three-, four- or multiple-layer,contoured innersole.

In the method of manufacture, the two-component or multiple-componentelastomeric urethane is mixed just prior to or with injection into themold cavity. An upper, flexible sheet material is laid over the moldcavity, usually after injection and prior to full expanding and fullcuring of the elastomer, so that the expandable, curable, elastomericresin expands into close, intimate bonding contact with one surface ofthe sheet material in the closed mold cavity, and then cures at leastpartially in the mold.

Generally, where a last material is used, the material is placed in themold and the urethane is injected over it. Generally, the exotherm is120° F. or greater and the curing takes place, to provide an expandable,at least partially cured elastomeric polyurethane foam in a time periodof from about 1 to 15 minutes, such as from 2 to 12 minutes, with fullcuring occurring generally during the next 12 to 24 hours, which, ofcourse, may be accelerated by the employment of heat. The elastomeric,cure foam material, comprising the heel or the remaining section,typically has a compressive strength of at least about 15 pounds orgreater and has a low compression set, so that it is substantiallynondeformable during use by the wearer, such as an ASTM compression setnot greater than about 20%; for example, less than 10%. More typically,the cured urethane foam is substantially open-cell in nature, isthermosetting or at least partially cured or fully cured, and has a lowfoam density; for example, 4 to 20 pounds per cubic foot.

The contoured innersole material of the invention and the process ofpreparing the same will be described for the purpose of illustrationonly in connection with certain embodiments; however, it is recognizedthat various changes, additions and improvements may be made to theillustrated innersole material and process, all without departing fromthe spirit and scope of the invention.

The method of the invention will be described for the purpose ofillustration only, employing an open-molding technique; however, it isrecognized that the molded innersoles of the invention can be preparedemploying a reaction/injection-molding technique, wherein the reactedelastomeric urethane is injected directly, at a low or high pressure,into a closed mold, either premixed or mixed during the injectionprocess.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-3 represent schematic illustrations of the steps of the processof preparing the shoe innersole of the invention;

FIG. 4 is a perspective view of a contoured shoe innersole of theinvention;

FIG. 5 is a sectional view of the innersole of FIG. 4;

FIG. 6 is a bottom plan view of the innersole material of FIG. 4; and

FIG. 7 is a sectional, illustrative view of another shoe innersole ofthe invention.

FIGS. 8 and 9 represent schematic illustrations of the steps ofpreparing a multilayer molded shoe innersole of the invention.

DESCRIPTION OF THE EMBODIMENTS

FIG. 1 shows an injection-molding system 10 comprising an open moldhaving a male mold section 12 and a female mold section 14, with dual,contoured heel and arch female cavity sections 16 and male contouredsection 18, which mold sections form a dual mold cavity of desired size.FIG. 1 shows the employment of a thin, blister-like, rigid, translucent,polypropylene resin sheet insert 20 containing a heel and arch cavitysection 22, to match the dual female cavity section 16 in the femalemold 14. In use, a mold-release lubricant may be employed in connectionwith female and male mold cavities 16 and 18; however, it has beendiscovered that the employment of a thin, female-mating, blister-typepolypropylene resin or other olefinic resin insert 20, employed in thefemale mold 14 to match the female cavity 16, is desirable, since thedual mold section 20 may be removed, together with the dual molded heeland arch section, directly from the open mold cavity. FIG. 1 shows themold in an open, hinged position, ready for the insertion of thepolypropylene resin insert 20.

FIG. 2 illustrates the mold sections 12 and 14, with the mold in theopen position and with the polypropylene resin insert 20 in position inthe female mold section 14. The illustrations as to FIGS. 1 and 2 are toa dual mold cavity; however, it is recognized that single- ormultiple-mold cavities may be employed as desired. Further, FIGS. 1 and2 are directed to a manual-type operation; however, it is recognizedthat the mold sections 12 and 14 may be placed on a linear conveyer beltor a round table, or otherwise the operations can be formed in asequential, periodic or continuous manner. FIG. 2 illustrates theinjection of a two-component, premixed, expandable, elastomericpolyurethane polymer 24 directly into each of the female mold cavities22 of the insert 20. After injection of the expandable urethane, areaction occurs with the generation of an elastomeric foam, with anexotherm occurring by the reaction of components which are premixed justprior to injection into the mold cavity 16. After injection of thepredetermined amount of the polyurethane and prior to the full expandingand curing and generally immediately thereafter, such as from 1 to 15seconds later, a flat, flexible sheet material 26, to be employed as anupper sheet, is introduced and placed over and on top of the insert 20and over the cavities 22 containing the reacting polyurethane 24. Ifdesired, the sheet material 26 can be positioned in the female moldcavity 22 prior to the introduction of the foamable polyurethanepolymer.

Sheet material 26 comprises, for example, for the purpose ofillustration, a fabric top surface 36, typically, for example, a wovencotton or a knitted polyester-type material bonded or secured to a layerof a vinyl open-cell foam or a latex open-cell foam 50. In the processillustrated in FIG. 2, the sheet material generally is greater in sizethan the female mold cavity 16 and is not yet shaped into a half- orfull-foot shape, but rather is used in block form. However, it isrecognized that, if desired, the upper flexible sheet material 26 may beemployed in the desired foot-shape form. In the process illustrated, theblock form material 26 is placed over the insert 20, prior to closingthe mold. The flexible sheet material 26, of course, may comprise athin, solid material, such as from 3 to 50 mils or lower, a foammaterial; for example, from 5 to 200 mils, or merely a fabric materialor any combination thereof. The sheet material 26 selected for use mustbe capable of being bonded directly to the elastomeric urethanematerial. If desired, a nonskid fabric material may be employed with themultiple-layer material, with the fabric or nonskid material forming thebottom surface of the sheet material.

FIG. 3 is a schematic illustration showing a blocker sheet 28 as removedfrom the mold, containing two, preformed, cured, contoured, molded,elastomeric foam, polyurethane heel and arch sections 30 directly bondedto the bottom foam surface of the sheet material 26. In FIG. 2, the moldis closed, and the injected, elastomeric polyurethane material 24 isallowed to react and to expand directly into contact with the bottomsurface of the sheet material 27 and, on curing, to bond directlythereto. The insert 20, with the blocker sheet 28 therein, is removedfrom the open mold after the molding operation, and the blocker sheet 28is easily stripped from the insert 20 and the cavities 22, without theneed to employ mold-release agents. If desired, curing of theelastomeric urethane may be accelerated by preheating the mold or thesurface of the mold, or later by placing the blocker material 28 in anoven to accelerate curing, or retained in storage for 12 to 24 hours tocomplete curing. After curing of the blocker sheet 28 is completed, theneach of the bonded, molded, respective heel and arch sections 30 areremoved from the blocker material 28 through a cutting operation, suchas the employment of a die cutter 48, to stamp out a shoe innersolehaving the desired shape and size, with the shoe innersole shown indotted lines on the blocker sheet 28.

The shoe innersole 34 produced by the process of FIGS. 1-3 isillustrated in FIGS. 4 and 5. The innersole 34 has an upper, wovenfabric surface 36 which is contoured in shape to the upper portion ofthe heel, with the heel section 30 formed of a cured, nondeformable,urethane elastomeric foam material of about 8 to 12 pcf density andgenerally having a flat, bottom, one-half section and another smoothskin layer.

FIG. 5 is a one-half sectional view of the innersole 34 of FIG. 4, whichshows the bottom surface 38 formed of the foam layer 50, and showing theurethane heel and arch sections contoured just generally under the arch,to meet in a gradual, tapered manner the flat bottom surface of the foamsection 38.

FIG. 6 is a bottom plan view of the innersole 34, showing the flatbottom surface 38 and urethane elastomeric heel and arch sections andshowing a diagonal-shaped, tapered line 40 of the heel and arch sectionsgradually contoured and extending from one to the other side of theforward part of the arch of the foot, with the elastomeric urethane foamformed under the arch of the foot, the generally uniform foam layer 50extending around the entire peripheral portion of the heel and under thearch of the foot, to provide arch support and comfort, with the line ofdemarcation between the flexible, lower, foam layer of the sheetmaterial 50 and the polyurethane foam of the heel section 30 asillustrated by line 40.

FIG. 7 is a sectional view of a modified shoe innersole 60, wherein arigid last material is also employed; thus forming a shoe innersolehaving a rigid last material 42 forming the bottom of the innersole, thelast material 42 shaped in the form of a full foot and inserted into thefemale mold cavity 16, prior to the injection into the mold of thepolyurethane elastomer 24. The innersole includes a molded heel section44 directly bonded to an upper, flexible material 50 formed of aflexible, thin layer of open-cell foam having a fabric surface 36. Theupper surface of the last material 42 and the lower surface of the foammaterial 50 are bonded by a thin adhesive layer 58, such as a urethaneor other adhesive, forward of the urethane foam arch and heel sections44, to form a composite innersole material having an integral lastmaterial, both bonded to the urethane foam material 50.

FIGS. 8 and 9 represent a further process 70 for preparing a shoeinnersole as shown in FIG. 7 or wherein two innersole sheet materialsare used to provide a molded full sole shoe innersole having lower lastmaterial and an upper open-cell foam material. The process 70 employsthe mold as illustrated in FIG. 1, except the resin insert 20 need notbe used. FIG. 8 shows the mold in the open position with a flexibleinnersole sheet material 26 composed of an open-cell foam layer 50 and afabric layer 36 ready to be placed in the female mold cavity 16.Elastomeric urethane is shown as introduced on top of the innersolesheet material 50, while a still shoe last material 72 is placed on topof the introduced elastomeric urethane prior to placing the mold in theclosed-mold position to permit the elastomeric urethane to expand andreact into contact with the opposing surface of the shoe last innersolematerial 72 and the flexible innersole material 26. FIG. 9 illustratesthe multiple layer blocker sheet 74 containing the expanded, reactedmolded elastomeric polyurethane material.

As illustrated, the shoe innersole of the invention has generallycontoured, elastomeric urethane, foamed, one-half heel and archsections. However, it is recognized that the polyurethane resin may beinjection-molded into a complete shape of a foot, with the elastomericurethane foam extending not only to contoured heel and arch sections,but also to and including a generally flat, uniform foam layer in theshape of a foot, if desired, to take the place of foam layer 50.

The method of preparing the innersole of the invention has beenillustrated employing an elastomeric urethane mixed outside of the moldand injected after mixing into the open mold. Thus, there is provided aunique, inexpensive, improved, molded innersole material suitable foruse in articles of footwear for comfort, heat insulation, heel supportand, if required, as a component of the shoe, where a last material isemployed.

What is claimed is:
 1. A method for manufacturing a molded shoeinnersole, which innersole comprises a contoured heel and arch sectioncomposed of a substantially open-cell, elastomeric polyurethane foammaterial directly bonded to an innersole sheet material and which methodcomprises:(a) providing a mold composed of a male section having a maleelement and a female section having a female cavity, the mold sectionsadapted to be placed in an open and a closed mold position, which moldin the closed mold position defines a contoured heel and arch moldcavity; (b) placing the mold in an open mold position and introducinginto the female cavity an expandable, reactable elastomeric polyurethanematerial to form the heel and arch section of the innersole; (c)introducing between the male and female mold sections while the mold isin the open position an innersole sheet material, the inner sole sheetmaterial introduced prior to introducing the expandable, reactableelastomeric polyurethane material or immediately after introducing theexpandable, reactable elastomeric polyurethane material; (d) placing themold in a closed mold position to permit the introduced polyurethanematerial to expand and react within the mold cavity into contact withthe innersole sheet material, so as to provide a blocker sheet composedof a reacted, expanded foam elastomeric polyurethane heel and archsection directly bonded to the introduced innersole sheet material; (e)placing the mold in an open mold position and removing the blockersheet; and (f) optionally, cutting the blocker sheet to provide a moldedshoe innersole for footwear.
 2. The method of claim 1 wherein theexpanded, reacted elastomeric polyurethane material has a foam densityranging from about 4 to 20 pounds per cubic foot.
 3. The method of claim1 wherein the expanded, reacted elastomeric foam polyurethane materialhas a compressive strength of about 15 psi or greater.
 4. The method ofclaim 1 wherein the expanded, reacted, foam elastomeric polyurethanematerial has an ASTM compression set of not greater than about 20percent.
 5. The method of claim 1 which includes premixing thecomponents of the reactable and expandable elastomeric polyurethanematerial just prior to introducing the expandable, reactablepolyurethane material into the female cavity, and which elastomericpolyurethane material provides a reaction exotherm to a temperature ofabout 120° F. or more.
 6. The method of claim 1 which includes expandingand reacting the polyurethane material in the closed mold for a periodof from 1 to 15 minutes and removing the blocker sheet from the openmold position and completing the cure of the polyurethane material. 7.The method of claim 1 wherein the innersole sheet material comprises aflat, flexible sheet innersole material.
 8. The method of claim 1wherein the innersole sheet material comprises an open-cell, foam sheetmaterial having a fabric layer secured to at least one surface thereof,which fabric layer forms the upper surface of the molded shoe innersole.9. The method of claim 8 wherein the open-cell innersole sheet materialcomprises a urethane, vinyl or rubber latex-type foam sheet material.10. The method of claim 1 wherein the innersole sheet material comprisesa vinyl, urethane or natural leather innersole sheet material.
 11. Themethod of claim 1 wherein the innersole sheet material comprises a shoelast material wherein the shoe last material is bonded directly to thelower surface of the molded shoe innersole.
 12. The method of claim 1which includes trimming the blocker sheet by die-cutting the blockersheet to the general shape and size of a shoe innersole for use infootwear.
 13. The method of claim 12 wherein the innersole sheetmaterial comprises a fibrous resin impregnated flat footwear lastmaterial.
 14. The method of claim 1 which includes:(a) placing a thin,preformed resin liner having a female cavity contoured approximately theshape of the female mold cavity of the mold over the female mold cavity,the resin liner material not adhereable to the elastomeric polyurethanematerial to be introduced; (b) introducing the elastomeric polyurethanematerial into the female mold contour of the resin liner; (c) placing ashoe innersole material on top of the introduced elastomericpolyurethane material prior to placing the mold in a closed position;(d) removing the resin liner material with the blocker sheet therein;and (e) stripping the blocker sheet with the molded urethane heel andarch sections from the resin liner.
 15. The method of claim 14 whereinthe resin liner material is composed of a rigid polyethylene orpolypropylene resin material.
 16. The method of claim 1 which methodincludes:(a) introducing a first innersole sheet material between themold sections in the open mold position; (b) introducing an expandable,reactable elastomeric polyurethane material into the female mold cavityand onto the first innersole sheet material; (c) introducing a secondinnersole sheet material onto the introduced polyurethane material; and(d) placing the mold in a closed mold position to permit thepolyurethane material to expand and react to provide a molded foamelastomeric polyurethane heel and arch section directly bonded to theopposing surfaces of the first and second innerole sheet materials. 17.The method of claim 16 wherein the first or second innersole sheetmaterial comprises a shoe last material to form the bottom surface ofthe molded innersole and the other innersole sheet material comprises aflexible innersole sheet material to form the upper surface of themolded shoe innersole.
 18. The method of claim 16 wherein the first orsecond innersole sheet material comprises an open cell foam sheetmaterial having a fabric-type surface to form the upper surface of themolded shoe innersole.
 19. The method of claim 1 which comprises cuttinga molded shoe innersole from the blocker sheet, which shoe innersole hasa full sole shape.
 20. A method of manufacturing a molded shoeinnersole, which innersole comprises a contoured heel and arch sectioncomposed of a substantially open-cell foam elastomeric polyurethanematerial directly bonded to an innersole sheet material and which methodcomprises:(a) providing a mold composed of a male section having a maleelement and a female section having a female cavity, the sectionsadapted to be placed in an open and in a closed mold position, whichmold in the closed position defines therein a contoured heel and archmold cavity; (b) placing the mold in an open mold position andintroducing into the female cavity an expandable, reactable, elastomericpolyurethane material to form the desired heel and arch section of theinnersole; (c) introducing into the mold in the open position a flat,flexible innersole sheet material, the innersole sheet materialintroduced immediately after the introduction of the expandable,reactable elastomeric polyurethane material; (d) immediately closing themold sections to place the mold in a closed position to permit theintroduced polyurethane material to react and expand in the mold cavityinto contact with the innersole sheet material to provide a blockersheet composed of a polyurethane foam heel and arch section directlybonded to the innersole sheet material; (e) opening the mold andremoving the blocker sheet; and (f) cutting the blocker sheet to providea molded shoe innersole.
 21. The method of claim 20 which includes:(a)inserting into the female mold cavity while the mold is in the openposition a thin, preformed resin liner having a contoured female cavityapproximately that of the female mold cavity; (b) introducing theexpandable, reactable elastomeric polyurethane foam material into thefemale cavity of the resin liner; (c) removing the resin liner and theblocker sheet from the mold in the open position; and (d) stripping theblocker sheet from the resin liner.
 22. The method of claim 20 whereinthe flat, flexible innersole sheet material comprises an open-cell foaminnersole sheet material having a fabric surface, which fabric surfaceforms the upper surface of the molded shoe innersole and which includesplacing the shoe innersole sheet material with the open cell foam overthe expandable, reactable elastomeric polyurethane material to provide adirect bonding between the expanded, reacted foam elastomericpolyurethane material and the open-cell foam shoe innersole sheetmaterial.